Cable joint and method and means for forming same



E wxLLlAMs :TAL 2,236,863 CABLE JOINT AND METHOD AND MEANS FOR FORMING SAME med Nov 15 1939 INVENTORS E19/V557' W 5 sheets-sheet 2 Apnl 1, 1941 API'U, 1941- E. wrLLxAMs ETAL 2,236,863

CABLE JOINT AND METHOD AND MEANS FOR FORMING SAME Filed Nov. 15, 1939 s sheets-sheet s ATTORNEYS April 1, 1941.

E. WILLIAMS ETAL 2,236,863 CABLE JOINT AND METHOD AND MEANS FOR FORMING SAME Filed Nov. 15, 1939 5 sheets-sheet 4 W @agita will ATTOR NEYS INVENToRs E57 w/L/ 5 Sheets-Sheet 5 Jill E. WILLIAMS ETAL Filed Nov. 15, 1959 H Hp EEN 60A/5 BY CABLE JOINT AND METHOD 'AND MEANS FOR FORMING SAME April 1, 1941.

Patented Apr. l, 1941 y d 2,236,863 v csnmsonvr No mon AND Menus FOB FRMING SAME Ernest Williams, .lackson Heights, and Constantine l Xenil. Little Neck, N. Y., a'ssignors to Consolidated Edison Company of New York, lynor New York, N. Y., a corporation of New Application 'November 15, 1,939, Serial No. 304,56*! il. Claims. (01133@112) This invention relates to improved cable joints and novel methods and means tor forming same, v and is particularly applicable to Joints in electric power cables and electrical communication ruining thejoint or the cable. Also, particularly with the' larger joints, if the plastic mass oi solderes it accumulates on the joint is slightly too soft, it may collapse and fall away, requiring wire cables of the typesencloscd in lead or other l5 the operative to start anew. Againyif thejmass metallic sheaths. v

This application is directed to varlom alterneltive embodiments vand improvements oi the in-1 ventions of our copending application Ser. No.

oi solder solidies before a smooth continuous wipe has-been formed, crevices and irregularities will occur impair-lng the `streng-th and durability oi the seal or adording areas prone to leakage.

304,566iiled on even date herewith, entitled Cal0 While such an imperfect joint sometimes might ble joints and methods oi forming same.

Join-t constructions for lead covered cables and the like are customarily covered, protected and strengthened by a lead or other metallic sleeve be corrected bynpplying a blow torch, the use of open dames in underground manholes or passages offers a hazard from gas explosions and is therefore generally prohibited. There is a relaenclosing the spliced portions of such cables For l5 tively narrow temperature range oi plasticity remany years it has been the practice to eiiect a/ seal Ibetween the endsot auch sleeves and the cable sheaths -by beating in the ends of the sleeve to an extent such that the peripheral edges contact with the cable sheath, and then the re- 2o type of work, has a plastic range of approxikgion at the end oi' the sleeve is wiped" by hand with solder chilled to plasticity. such wipingr operation has to be performed by skilled workmen who have gone through 'a `considerable period of training if the occurrence oi' leaky or 25 cooled to a plastic Workability,y there vis e. solidporous wipes is to be avoided,even with cables o! relatively small size. However, with the use oi cablesof larger size requiring larger wipes, and particularly with complicated joints or where of the joint, there is, great diiiculty in securing reliable wipes and only a small portion of thev more skillful and experienced workmen trained in this/art are able to accomplish the task, and

mately 55 C., or from about 238 C. down to 183 C.," the latter temperature being the solldifylng point of the eutectic mixture (63% tin and 37% lead). In the wiping process as the solder is iilcation of lead particles or crystals at temperatures above 183 C., the solidifying point of the eutectic mixture.l Yet due to the fact that the eutectic mixture remains liquid down to 183 C.,

. two or more cables enter the sleeve at one end 30 it tendsto run out of or to the bottom of the mass being formed, leaving the wipe coarse or Jporous. toward the top. This effect is particularly pronounced in larger wipes. For example, it has been found very diillcult to secure reliable sometimes the operations fail and have to be 35 non-porous wipes on the larger cables without rerepeated before successfully completed.

In performingX the wiping operations, solderis melted in apot, and then poured by the use df a hand ladle on to the areaoi the desired wipe.

` sorting to the hazardous glazing process.

Further disadvantages of the customary wiping process reside in the following facts. The necessity of maintaining a pot of the molten metal at A' portion of the solder thus,y poured adheres in 40 hand, particularly inconilned spaces during unplastic condition to the cable sheath or fthe sleeve, provided the poured solder is'at the proper temperature, and the remainder is received in a wiping pad held in thehand 'of the operative just yarea. ot the desired seal until a sumcient mass of plastic solder is built up to form a poultice-like dei-ground work, is a,dangerous hazard, as is2 also the'ladling and pouring of such metal. The opreratives are frequently seriously burned. The beating in of the sleeve for complicated joints beneath the cable. This pouring operation is 45 requires much time, vand skilled work. Often repeated again and again, while the pad with jsolder thereon must be skillfully wipedover the quires the services of, the skilled operative for seal between 4the sleeve and 'the cable sheath. 50 several hours even li the operations do not have ,The dimculties with this method ariseix'om various causes. I! lthe solder is too hot ori! too much solder is poured on to one area, either the sleeve or cable sheath willf'be burned" quickly to berepeated'. And the quality and useful life of the resultingjoint often depend largely upon Y V chance or the skill of the workman. n

While ettorts have been made for years to ypro-` through, 'that is. a hole will-.be4 melted through, 55 vide some method of avoiding the above diiiicul- Athe mold of Fig. l10,

ties and hazards, so faras lwe are aware such efforts have "not, prior I'to our inventions, produced any substitute method or construction which has gone into anyV substantial practical' v. use in replacement of the manual wiping operation. Y -z 'Ihe objects of this invention include the PIO,-

vision of improvedjoint constructions and methisfactory seals, with a substantial saving of time and without requiring the operative -to have any the problem of sealing metallic sheathed cables within terminal bushings or the like, for example at points where the cables enter a transformer or other piece of electrical equipment.

Various further and more specific objects, features and advantages will clearly appear from the detailed description given below' taken in connection with the Jaccompanying drawings which form a. part of this specification and illustrate merely by way .of example preferred forms of the invention. The invention consists in such,-

novelmethods and method steps, features, ar-

rangements and combinations of parts as may be `shown and described in connection with the constructions herein disclosed.

In the drawingsl' k n l l `AFig.`l illustrates a plurality of cable ends to be spliced, and also showing a desirable preliminary arrangement of the' parts to be used in forminga cable joint according to the invention,

' Fig. 2 is a view similar to Fig. l but illustlat-` ing the next steps' in forming the joint, after the cable ends have been spliced and electrically inf svulated, A

Fig. 3 illustrates the positions of various parts of the cable joint during a succeeding sten,

Fig. 4 is' an end view showing the partsof a molding means which may, for example, be ap plied to the cables at the left-hand end of the joint of Fig. 3, f

Fig. 5 is a view similar to Fig. .3 but showing molding means applied to both ends of the joint Sancxll filled with solder for sealing the ends of the o t. n v,

uFig.;ij is aside view of a completed cable joint showing lthe manner in which the mold parts may be removed,

Figs. I and 8 respectivelyare perspective views of the finished seals at the left and right-hand ends of the cable ioint of Fig. 6,

Fig. 9-is a perspective view of an alternative form of mold,

Fig.- lo is en elevational view e: the latter nold, 11 is a sectional view taken substantially l along the linel l I l| of Fig. 10,`

Figs. 12 and laillustrate certain detalls of Fig. 14 is a diagram of the eleetrleel heater connections for a Fig. l0, (Y Fig. 15 is an end view of a barrier member which may be used in forming a joint as of Fig. 5, `fior example,

Fig. 16 is a sectional view taken substantially along the line I|I of Fig. l5, y j Figs. 17' and 18 respectively are face and top mold, such for example as of views showing` further details 01a mold sueltas 1 75 n.19. wltlitllel sleeve napiaee, ltinay` '0i' Fig. 44,

Fig. 19 is a sectional view maken substantially high degree of skill or long-experience. Variousll ber similar to that of Fig`. 15 but adapted for refeatures of the invention are also applicable to 20" cable ends, as at 30, 3i, 32, 33, are shown comend, to another cable end, 'or to joints having a of the joint.

gaskets (as at 35, 36, 3l) and metallic barrieris provided.

to theregion of the splices. After the splicing the cables at its desired permanent position and (Fig. 2).and tacked in position'witll solder.

along the line I9- |9 of Fig. 1'7, l l

Fig. 20 is a view of one of the parts of the mold of Fig. 1'? and taken substantially along the line Fig. 21 is a face view partly in section of an alternative form of a three-part mold,

Fig. 22 is a sectional view taken substantially along theline 22.-22 of Fig. 21 allowing the mold as applied in use to a joint construction, e

Fig. 23 is a top view of the mold-of Fig. 21, Fig. 24 is-a perspective view of a flnished'seal as made with a mold as of Fig. 21, for example,

Fig. 25 is a face view of another barrier memceiving and supporting three cables; and

Fig. 26 ,is a sectionalI view taken substantially alongthe line 26--26 of Fig. 25.

Referring now to Figs. 1 to 3: a pluralityv of ing into one end of a proposed joint, and a single cable end 34 is shown for coming into the other end. -While the particular joint here shown is a so-called "one-'way :c four-way joint, it will be lunderstood that the invention is equally applicable to either simple joints of a single cable members as at 38, 39, the construction and pure poses Jof which will be explained hereinafter. Y Also a metal sleeve as at I0 for enclosing the finished joint may be placed upon the cable end or ends atone'side of, the proposed joint..- This sleeve is preferably and usually made of lead and is preferably cylindrical although other tubular shapes may be used if desired. Usually also an ,inner sleeve as at Il of rigid insulating material Suitable insulating electrical joints or splices may be made between the various cable ends as shown at I2 according to well-known methods which need not be here 0 will be apparent that during the work of making the"electrical connections and the insulation thereof at 42, the sleeves I0, Il, as well as the barrier members and gaskets, may be slid back along the cables far enough to afford ready access andthe insulation work are completed, as at 42', the insulation sleeve 4I may-be slid over the spliced region to the position shown in Fig. 2. The inner surfaces at the ends, and the ends of the sleeve l0 are scraped clean and coated with stearln or other flux material, and the surfaces of the cable sheaths and barriers at the areas of the desiredseals are similarly prepared. Then the barrier member, as at 38, may be placed along tacked with solder to each of the cable sheaths, a as at 43, M. Similarly, the barrier member 39 may be positioned on the cable at its desired permanent position, as indicated in dotted lines Thereupon, the sleeve 40 may be` slid into a position suchy as shown in Fig. 3. The ven/ds of th sleeve 40, lf desired, may besligthly flared t enable the sleeve to readilyslide overjthebarrier further described. It'

accesosY Y tacked with'solder as at '45, 49 with'respet the barrier members 38, 39. If necessary, before this is done, the' outside surfacesof the ends off the sleeve may be tapped circumferentially inV order to cause them to fit tightly around the barrier members 38, 39. Y The barrier member 39, as shown in further detail in Figs! 15 and 16, may comprise a dis'clike member pressed for example, from sheet lead so as to have an extended peripheral ange, as at 41, designed to extend inwardly of the joint for a considerable distance in contact with the a rigid and extended joint between such wall and insidewalls of the leadsleeve 40, so that. when.

- moltensolden is appliedy to the outside surface ci the barrier for sealing the joint, any solder which may tend to leak inwardly along the lnside" surface of the sleeve will have opportunity 5 to/become cool and solidify, thereby preventing 'leakage ofsolder into the joint past the flange di.' The centralarea of the barrier member 39 the cable therethrough. The inner walls of the aperture. as shown (Fig. 16) are preferably shaped with a generally conical ange extending inwardly ofthe Joint, ,so that the more restricted portion 49 of this ange may closely embrace the cable sheath.

'The external dimensions of lead cable sheaths of various speciiied sizes, often do not accurately conform tothe dimensions speciiled. Consequently in order to insure that the apertured barriers -will closely fit the cable sheath, it is necessary to provide for varying the aperture size on each job. This may be readily accomplished withthe construction shown, by forming A the constricted portion 49 with a diameter small enough to insure a close t with the smallest Cable intendedl'to pass therethrough and for able en the finished joint, lt may be readily sled 40 desired. l

slightly larger cables the constricted'portion may be roamed, or expanded somewhat as by a coniciily shaped tool. 'I'hebarrier 33 for 'accom-` modating a plurality( of cables such as at the other end of the joint shown, may be sim' to the barrier 39, except,as indicated in Figs. and 26,/.an appropriate number of cable apertures may be provided as at 50, each with conical anges im at 5l corresponding in construction and purposes to the conical'ilange in the barrier 39 as above described. f y

After the barrier 38 and 39 and the sleev'e`4ll are ln position as s `ovm in Fig. 3, packing in themay be apertured es at 48 to permit passage of,

each cable sheath is provided, ample to Withstand the :forces to which the cables may be subjected and sumciently extensive so that any danger of leakage along the cable sheaths is avoided. Althoughthe wall 54 is substantially flush with the end f the sleeve (t, the mold for forming same may preferably be so shaped as to provide ka narrow radially extending peripheral ange of solder as at 6l sulcient to cover and protect the edges of the sleeve and to prevent,anydanger that the wall may be dislodged inwardly of the joint. The mold for making the wall 54 -is preferably so shaped that the gate or sprue will be 'formed atthe location indicated at 62 in Fig. '1. A

That is, the sprue as shown, extends from the uppermost ilange` or anges asat 51,58 along theA outside face of the wall 54 to a point'adjacent and just above the upper end edge of the sleeve 40. The gate in this position will insure direct access of solder to the spaces for the uppermost Y ai'iges'as at 51, 58 even though the final amounts of solder may be introduced after the remainder of the solder in the mold is partially hardened,

according to the methods hereinafter explained. Whilethe spruein this position is not objectionor 'cut away after completion of the joint if so lprime marks so that the details of construction i'orm .ot lead wool or lequivalent means -may be l inserted as at' 52,- 53 around each of the cables within the' conical'fianges at the barier apertures. The joint Jis now readyfor application of molding means for forming a seal of solder at each end of the joint as shown in Fig.,5.l

The molding means at each end of the joint is A preferably so shaped as to cast a disc-like wall l'of solder within each end of the sleeve 43 for .integrally seellngllie eeble sheaths ln respect to the inside walls and end edgesof thev sleeve. Fig. 7 is a. perspective view showing the appear- Aance of a preferred form of such a seal-for the lefthand end of thevjoint .of Fig. 5. It will be noted met the well. or. the, solder leflergely wlm- 'in the end of the sleeve and -thereforeis in a.

.andJpurposes oi` these features in Fig. 8 will be,

apparent from the above.

"An example of a suitable molding means for the seal at the lefthand Kend of Fig. 5 is illustrated in Fig. 4 with theparts in separated condition. As shown this mold may be made `up of 'three sections as at 63, 64, 65, each extending from side to side of the group of cables and havof lugs for clamping the several sections in respect to each other and at the same time serving to clamp the mold parts in respect to the end of the sleeve 40 and to the cable sheaths.A It will be noted that each of the mold sections is provided with semi-circular recesses as at *14 for embracing one-half of each cable, and the adjacent -mold section in each case being provided Lposition to aiford mutual support between the sleeve end edges and the cable sheaths, whereby internal rpressures as well as being' capable of 'Y with a complementary recess for embracing' the Aother half ofeach cable. Withthe niold sections thus extending froln'side to Lsideand with the clamping Inflleans and recesses asshown. the secitfithstandin-g' machinal shocksand repeated ex' tions may be quickly and conveniently applied .and removed vfrom the groupv of' cables and the various cables may be clamped in position with .lllFisfl' itvitl;-be further' noted that-theta'- 75- uniform pressure@ each Without danser of excess' pressure at any point such as would injure the sheaths.

At the'righthand end of the particular joint shown in Fig. 5, molding means as a't 15, 16 similar to-that of Fig. 4` may be provided, except .thatthe mold 15, 16 need have but twosections to provide for the single c'able 34.

Each of the mold'sections mayl be formed with a plurality of cavities as at 11 opening at the outer face of the mold but closed at their inner ends adjacent the inner face of the mold. Each of these cavities isfadapted to slidably and re'- movably receive electrical heating elements of the well-known cartridge type. Further details of construction of the molds and modications thereof will be vdescribed hereinafter.

After themolds have been applied to each end of the joint, the `gaskets as at 35, 3B and 31 may be forced into annular spaces provided therefor Within the fcable recesses of the mold-sections,

, as shown in Fig. 5. These gaskets may be formed of cork or other suitable material or composition capable of withstanding the temperature of mol-A ten solder and preferably a somewhat yieldable material which may be pressed rmly into place to prevent passage of molten solder outwardly along the surfaces of the cable sheath or along the surfaces of the mold recesses during formation of the seals. A composition of cork and synthetic rubber known in the trade as Coprene azasea l melt down the` solder seals without injury to the lead cable sheaths or the lead sleeve, whereupon thel sleeves may bev slid away and the splice in" spected or renewed or readily replaced byY a splice with additional or larger cables, for xample. Then the joint may be sealed again as before. Or if a larger joint is` necessary, ythe sleeves may be removed for reuse elsewhere and larger sleeves, barriers, etc., may be substituted.

The introduction of the solder in thedivlded solid forms as above explained, is particularly advantageous in that none of the solder needbe made molten until after'lt is in place within the joint and thus the hazards of maintaining a `quantity of molten solder and handling same are eliminated, as are alsotherdiiiiculties o f tim-v ingthe workmans motions to avoid applying or introducim the molten solder,- either too hot or too cool. It may be observed that if molten s older were to be poured into the molds, two sources of heat would be necessary in practice, one for preliminarily melting the solder and the other to heat the molds. Otherwise the molten solder when poured .into the mold gates might solidify on striking the cold parts :and preclude proper solderig'actionfor preventing filling of the mold. And if two sources of heat were thus used, there would still be danger that the molten solder would enter the molds at too high a temhas been found satisfactory. To prevent leakage Af solder at the edges ofthe sleeve 40, it may sometimes be found'desirable to insert packing material such as asbestos wicking or lead floss into an annular space 18 (Fig. 5) provided therefor at the periphery of each mold.

l A"Smallquantities of powdered stearin or other suitable i'lux as required may now be introduced through each of the mold gates as at 19, 19' and ,then the mold cavities may be filled through these gates with solder lin solid state but in such divided form that it may be substantially poured into the molds. Preferably this solder may take the form of rounded pellets or solder shot of somewhat less than 5/3? diameter, although in some cases granulated solder may' be used if desired. Grade 1, Class 1, solder shot comprised of 59% tin and 50% lead has been found satisfactory.v After the solder is'thus introduced, the

f cartridge heaters may be connected and a controlled amount lof current may be applied thereto for a limited time, suillcient to quickly melt the solder without overheating, injuring or melting the adjacent lead parts. After the mass of solder becomes molten, it may be allowed to cool while continuing to add through the gates further solder shot or stick solder or the like, sufficient to compensate for shrinkage las the cooling progresses. Breferably the cartridge heaters or the' current therein for the lower parts of the molds are removed first so that the lower portionsl of the solder seals will solidify and shrink while the-uppenportions are still in molten condition perature and thus melt holes through the lead sleeve, barriers or cable sheaths. However, by introducing the solder in divided solid state, all

of the heating may be readily accomplished by electrical means within the molds and ,under carefully controlled and safe conditions. Also the use of pellets or solder shot appears to offer the further advantage that when the same are being melted within the mold, they will abruptly and intermittently fall or 'slide over one another and over the surfaces to be soldered, in such -a way that the surfaces will bev mechanically smeared with the molten solder with a positive action, insuring `firm adhesion of the solder to the sleeve, cable 'sheathsand barriers. That is, the mass of pellets or shot as initially introduced will have a great many interstices or air spaces and the melting solder, in falling into these spaces, will promote the action above referred to.

The upperv surface of the sleeve 40 may preferablybe provided with a pair ofI apertures closed by screw plugs as at O0. These screw plugs are preferably removed during the sealing operations so as to relieve any gase pressures which might otherwise occur within the joint .due to the heating of the ends thereof. And after the-seals havebeen formedJ atthe lendsof the joint, suitable insulating liduid maybe poured in through L while the other acts as an air vent. f

one of these openings With the. methods and constructions-above described, :thas been round that operativeseven with little experience, are able to reliably seal f complicated and large sized splices in a fraction adapted to receive and melt the additional solder for making 4up the shrinkage. -After the seals have become solidified, the mold sections may be I removed as indicated in Fig, 6. The central mold -section Bt may be slid outwardly along the cables to a point where the slack of the cables will permit its removal. The gaskets as at 35, 31, etc., may preferably be-split as indicated in Fig.' 6 to faciltate removal and the same may be reused.

If'at any subsequent time, it is desired to open the joint, the molds'may be put in place again and suillcient 'heat thereby applied to readily of the time required for the usual wiping process.

At the same timethe operatives arenot subjected to the hazards ofworking around or with open masses of molten solder. There` is never any necessity of incurring the hazard of using anl open flame underground either to glaze the joint or for any other purpose,.and there is no danger of spilling the solder onto lthe workman, and

there is no loss from pouring excess solder, as

occurs with the wiping method.

Pressure tests made onjoints completed in accordance with this invention and under pracmotions of the operatives as necessary in pouring and wiping is obviated The time and skilled labor required for properly beating in and tting the sleeve end s and parts, for wiped jointsr are obviated, as are also the uncertainties an defects of such method.

While We are aware that attempts have h'eretofore been made to seal cable joints by the use of molds for .casting solder for the purpose, these attempts so far as we are aware did not obviate the necessity of beating iii and specially fitting the ends of the. joint sleeve. `Neither were the molds of such. form that ther solder could be introduced in divided solid state and then be heated under controlled conditions to.- overcome the numerous diiiicultiesfof the wiping method.

In practising this invention the solder comto the requirements for obtaining a plastic mixture. substantially homogeneous throughout, and the porosity encountered in hand formed wipes is Yet the resulting cast walls of solder are 'position used may be selected without adhering 25 eliminated. The solder mixture remains essentially constant as it is retained in the casting cavity.` t

` Since a definite plastic range is not required of the solder for this method, itis possible if desired chance of injury to the cable insulation.

Referring .now to further features of the-mold constructions, Figs. 17 to 20 inclusive comprise 'enlarged views of a mold such as Fig. 4. A desirbefore the gate is solidied. `The abutting face;

of the lmold sections should be accurately iinis7hed to insure a close fit and the surfaces may be xed against sliding with respect to each other during application of the 'mold as by pins 83. In

order that the mold sections may be good conductors of heat, while being light in weightfor convenient use, they are preferably formed of cast aluminum or aluminum alloy. Aluminum alloy known as No. 43 in the trade has proven satisfactory. The mold surfaces which are to be in Contact with the solcie. should be suitably treated as by a so-called anodizing process to prevent the solderfrom adhering thereto. Fig. 19 indicates the manner in which the cartridge heaters as at 84 of well-known construction may be inserted into the cavities 11. As shown in 1"?, each of the manualclamping elements may comprise for example a threaded stud as at 55, fixed in one of the mold sections and adapted y to be engaged by an internally threaded piece as at 86 whichwis iixed to a nger. piece 8l but is rotatably mounted within a, lug ontthe mold section.' This arrangement avoids the use of any loose pieces separate from the mold sections, so

that the use of thelmolds in'conilned unde'r- 75 Vto choose a solder mixture close to the eutectic,

thereby requiring less heat for melting, with less ground work for example is facilitated without danger of loss of parts.

In Figs, 9 to 13 inclusive, an alternative form of mold is shown with electrical heating means permanently embodied within the mold sections. The heating means here may comprise resistance elements permanently embedded withrefractory insulation in metallic tubes as at 88, 89 and of a type well known per se. These elements may be bent into arcuate form as shown in Fig. 10`and thencast withinthe mold .sections along the rei gion intermediate between the intended location of the cable sheaths and the joint sleeve. Suitable connections for these resistance elements are shown in Fig. 14. It will be noted that the ends of each element may be brought out to quick-detachable electrical terminals as at 90 to 9i inclusive, thus facilitating disconnecting the heating current from one of the mold portions while the remainder is stillheated for reasons above explained. As shown in Fig. 14, an electrical thermostat 88 of a suitable well-known construction may be placed in series with the circuit of sthe heating elements and shunted'by a condenser 99 to prevent arcing at the thermostat. The thermostat and condenser `may be mounted within suitable cavities therefor in one of the mold sections sofas to form a senil-permanent' part thereof as shown in Figs. 10 and 11. A suitable closure'as at |88 may be provided along one of the mold sections for housing the connections between the thermostat and the terminals 96, 91. f

In Figs. 21, 22 and 28 an alternative formof mold construction ls shown, which isadapted to be applied to a group o f three symmetrically lo# cated cables, Parts and features of these gures corresponding to those of Fig. 1 7 are identified by the same reference numerals accompanied by prime marks and accordingly the construction,

purposes and uses of this embodimennwill be apparent from the above explanations. The ex'- ternal appearance of the finished solder seal formed' with the mold of these vfigures is' illustrated in perspective in-Flg. 24. i

While the invention has been described in detail with respect to particularpreferred exam-v ples, it will be understood by thoseiskilled in the'- art after understanding theinvention that various changes and modications may be made without departing from the spirit and scope of the invention, and'it is intended therefore in the appended claims to cover all such changes and modifications.

Various features of the molding means herein disclosed are claimed in applicants copending application Sen No. 379,016, led FebruaryI 15, 1941. f

What is claimed as new and 'desired to be secured by letters Patent is? e 1. The method of sealing an insulated electric cable having a. metallic sheath, in respect to a metallic sleeve into the end of which the cable extends, which comprises placing barrier means around the cable, between the cable and `sleeve near an end of the latter to form an enclosure,

introducing aquantity of "solder in solid state y metallic sleeve into the end of which the cable extends, which comprises placing barrier means around the cable, between the cable and sleeve near an end of the latter to form an enclosure,

introducing a quantity of solder in solid state and in such divided form that it may be poured into said enclosure, and applying heat from. a source within the barrier means to melt said solder,"

whereby the resulting body of solder when cooled integrally seals the cable sheath in respect to the sleeve. y

3. The method of sealing an insulated electric cable having a. metallic sheath, in respect to a, metallic member receiving same, which comprises' placing a mass of solder pellets around the cable sheath at the'location of the desired seal, and melting said pellets whereby the resulting body of solder when cooled integrally seals the cable sheath in respect to said member,

4. The method of sealing an insulated electric .cable having a metallic sheath, in respect to a imetallic sleeve receiving the cable, ^which comprises providing a pair of spaced barriers forming va cavity therebetween and between the walls of the sleeve and the cable, lilling said cavity said member being formed at its periphery with 'a wide ange for extending along and incontact with the inside walls oi the sleeve for a sulcient distance inwardly of the joint so-that molten solder passing between said flange and said walls may become cooled and solidify before escaping into the joint.

8. Barrier means adapted to close the space between a cabiesheath and a cable joint sleeve, against passage of molten solder inwardly ofthe joint, comprising a disc-like metallic member, said memberlbeing apertured for passage of the cable therethrough, the aperture being formed with a generally conical ilange. the oonstricted portion of such ilange being adapted to closely embrace the cable sheath.

9. Barrier means adapted to close the space between a cable .sheath and a cable joint sleeve,

with solder shot, and melting said shot whereby the resulting body of 'solder when cooled integrally sealsthe cable sheath in respect to said 5. Means for sealinga metal-sheathed electrical cable within the end of a surrounding metal sleeve of larger diameter for enclosing a cable' joint, said means affording rigid mutual support between the cable and sleeve end and compris-` ing a disc-like .wall of solder substantially iiush at its outer `surface, with the end of the sleevej 4 and cast `in situ into integral sealing relation-- ship with the sheath and sleeve, the cable also Y being encircled by and sealed to aviiange of solder integral with said disc-like wa'll and extending outwardly therefrom along the cable sheath.

v- 6.- In a joint construction for metal sheathed' electrical cables, a sleeve surrounding the cable sheath in spaced relation thereto, means integrally vsealing the edges at the end of the sleeve s.

in respect to the cable sheath and aiording rigid mutual support between the sheath and sleeve, comprising a disc-like wall of solder cast in situ, the'cable also being encircled by and sealed to a flange of solder integral vwith said wall and ex'- tending outwardly therefrom along' the cable sheath, and a sprue yextending radially from said iiange along the outside surface of saidwall to .a point just outside the sleeve edge.

k7.V Barrier means 'adaptedtp closefthe space ybetween a cable sheath and a cable joint sleeve,

against passage of molten solder inwardly o! the joint, comprising a disc-like metallic member against passage oi' molten solder inwardly of the joint, comprising a disc-like metallic ,member, said member being apertured iol' Dasage of the cable therethrough, the walls or' the aperture being generally conical and extending for a sub' stantial distance inwardly of the joint to a constrict'ed portion for closely embracing the cable and adapted to receive packing means.

l0. The method of sealing an insulated electric cable having a lead sheath, in respect to a lead sleeve encircling the cable in spacedrelation thereto, which comprises inserting into the sleeve near lthe end thereof a permanent barrier ior closing oil the space between the cable and sheath, temporarily applying molding means embracing the cable and fitting the end of the sleeve to form an enclosed cavity within the sleeve and between the barrier and molding means, heatingl said molding means fr'om a source-therein to a controlled temperature of molten solder and lower thankthe melting temperature' oi the sheath and sleeve, while introducing a mass o! solder, including lead, filling said cavity, then discontinuing such heating. whereby said solder isvcast integrally with the sheath and sleeve, and inally removing said molding means.

l1. The method o! applyinga mass of solder in bonded relationship to a lead sheathcf an insulated electric cable, which comprlses temporarily securing to the sheatha mold having at the sur-), face of the sheath a cavity shaped in accordance" with the desired mass, introducing solder linx into said cavity, pouring a mass of solder pellets into said cavity, and melting said pellets by' heating said mold,-whereby the resulting body of solder-when cooled forms a mass integral with the lead sheath. 

